MECHANICAL ENGINEERING

DEPARTMENT

DJJ40142
MECHANICAL WORKSHOP PRACTICE
4

REPORT
(EDM WIRE CUT)
SEMESTER 4

NAME MUHAMMAD FAIZ HAZWAN BIN SYAMSUL

MATRIX NO 11DKM21F1072
CLASS DKM4A
LECTURER 1.TS.DR. KANNAN A/L RASSIAH
2. TN. HAJI ISHAK BIN IBRAHIM

1
 CONTENTS
No Title Page
1 INTRODUCTION 3
2 OBJECTIVE 6

3 SAFETY AND PRECAUTIONS 6

4 LIST OF COMPONENTS 7

5 PROCEDURES 8

6 RESULT 9

7 DISCUSSION 11

8 CONCLUSION 12

9 REFERENCE 12

2
INTRODUCTION
Computer Numerical Control (CNC) is a form of programmed automation where the
process is controlled by numbers, letters, and symbols. It was published upon the
discovery of Numerical Control (NC) in the year 1950. The term “CNC” is a generic
term which can be used to describe many types of devices, this would include plotters,
vinyl cutters, 3D printers, milling machines and others. CNC stands for Computer
Numerically Controlled and basically means that the physical movements of the
machine are controlled by instructions, such as co- ordinate positions that are
generated using a computer.
Wire EDM machining (Electrical Discharge Machining) is an electro thermal
production process where a thin single strand metal wire, along with de-ionised water
(used to conduct electricity) allows the wire to cut through metal by the use of heat
from electrical sparks, while preventing rust. Wire EDM machining works by creating
an electrical discharge between the wire or the electrode and the work piece. As the
spark jumps across the gap, material is then removed from the work piece and the
electrode. Due to the inherent properties of the process, Wire EDM can easily
machine complex parts and precision components out of hard conductive materials.
To stop the sparking process from shorting out, a non-conductive fluid or dielectric is
also used in the process. The waste material is removed by the dielectric, and the
process continues.

3
M Code
M-code (for “miscellaneous function”) is an auxiliary command; descriptions vary.
Many M-codes call for machine functions like “open workstation door,” which is why
some say “M” stands for “machine”, though it was not intended to.

M code Description
M 00 PROGRAM STOP
M 01 OPTIONAL STOP
M 02 PROGRAM END
M 03 SPINDLE CW
M 04 SPINDLE CCW
M 05 SPINDLE STOP
M 06 ATC / TOOL CHANGE
M 07 FLUSH COOLANT ON
M 08 COOLANT ON
M 09 COOLANT OFF
M 10 CHUCK / VICE UNCLAMP
M 11 CHUCK / VICE CLAMP
M 17 SUB PROGRAM CONTINUE
M 18 HEIGHT TOOL OFFSET CALL
M 20 ARM IN
M 21 ARM OUT
M 24 TOOL CLAMP
M 25 TOOL UNCLAMP
M 30 PROGRAM END REWIND
M 31 X- OFFSET CALL
M 32 TURRET CW / X+ OFFSET CALL
M 33 TURRET CCW / Z- OFFSET CALL
M 34 Z+ OFFSET CALL
M 35 DRILLING TOOL OFFSET CALL
M 38 DOOR CLOSE
M 39 DOOR OPEN

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G Code
G-code (geometric code) is the most common CNC (computer numerical control)
programming language used to drive computer-controlled manufacturing machines.

G Codes Function
G00 Linear interpolation at rapid traverse rate
G01 Linear interpolation at feed rate
G02 Circular interpolation clockwise
G03 Circular interpolation counterclockwise
G04 Dwell time
G18 Z, X-Plane (Standard turning)
G33 Thread cutting with constant lead.
G40 Tool radius compensation off
G41 Tool radius compensation left of contour.
G42 Tool radius compensation right of contour
G53 Settable work- offset–non-modal skipping.
G54 1st settable work offset.
G55 2nd settable work offset.
G56 3rd settable work offset.
G57 4th settable work offset.
G58 5th settable work offset.
G59 6th settable work offset.
G71 Metric dimension data input
G90 Absolute dimension data input
G91 Incremental dimension data input
G95 Feed rate F in mm/Spindle revolutions

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OBJECTIVE
• To acknowledge machine process capabilities and limitation
• To acknowledge CNC programming.
• To illustrate the Non-Traditional Machining Process using EDM Wire Cut
• To produce the NC programming for machining the specimen using EDM
wire cutting machine.

SAFETY AND PRECAUTIONS

• Wear appropriate eyewear, and never look directly at the spark.

• Wear closed toe, non-slip shoes with rubber soles.

• Never touch the electrode while the machine is in operation.

• Make sure only one person is operating the machine in a single time.

• Make sure there are no leaks in the tank dielectric liquid tank hose and
pipeconnections.

• Clear oily liquid that is in place of the working substance before work piece
installation process

• Make sure the work piece is installed properly and tightly.

• Clean all scraps in the tank desk and storage tanks.

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LIST OF COMPONENTS

EDM Wire Cut Machine.

for removing unwanted material by

applying cycled discharging sparks in
the gap between an electrode and a
conductive workpiece.

EDM Control Panel

to makes precise and accurate cuts

eliminating the need for further
processing and finishing of the
workpiece.

Working Table

place which is the process wire cut is

done

7
PROCEDURE

1. Firstly, the power button is turned on.

2. Then, the cooler switch is turned on
3. The safety button is released once the EDM switch is turned on to make the
machine operable.
4. The electrode pins and nozzles have been checked before putting the work
piece on the working table.
5. Make sure the wire and work piece are being mounted.
6. A 2D is drawn by using AutoCAD software.
7. After that, the drawing is insert into EDM wire cut machine.
8. The drawing information is programmed into the machine by using G code
and M code.
9. The programming is inspected before proceeding to the cutting process.
10. Auto button is pressed to check the position of the wire.
11. Once the programming started, the lower head and the upper head is moved to
the cutting plate by a jog.
12. On the control panel, the water switch is switched on for the inclusion of water
and related processes.
13. Start the machine to operate.
14. The machine is switched off when the cutting process has ended.
15. Lastly, cleaned the machine and turned it off.

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RESULT

NC PROGRAMMING

FINAL PRODUCT

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Programme Code

( = ON OFF IP HRP MAO SV V SF C PIK CTRL WK WT WS WP PC

SK);
C000 = 009 015 2215 000 260 +040.0 8.0 0100 0 000 0000 025 160 130 045 0000
00;
C001 = 009 015 2215 000 290 +040.0 8.0 0100 0 000 0000 025 160 130 050 0000
00;
H000 = +000000.0100 ;
H001 = +000000.1590 ;
( FIG-1 1ST ALL CIRCUMFERENCE);
QAIC(2,1,0.1250,000.3,0.1550,0.0100,002.0,0100,0115,15,035);
G54;
G90;
G92X4.1319Y23.4367Z0;
G29;
T94;
T84;
C000;
G41H000G01X4.1319Y20.0;
C001H001;
M98P0001;
T85;
G149G249;
M02;
;
N0001;
G01X15.0Y20.0;
Y14.0;
G02X9.0Y8.0I-6.0J0.0;
G01X0.0;
G03Y4.0I0.0J-2.0;
G01X5.0;
G02X15.0Y-6.0I0.0J-10.0;
G01Y-10.0;
G02X5.0Y-20.0I-10.0J0.0;
G01X-15.0;
Y-14.0;
G02X-9.0Y-8.0I6.0J0.0;
G01X0.0;
G03Y-4.0I0.0J2.0;
G01X-5.0;
G02X-15.0Y6.0I0.0J10.0;
G01Y10.0;
G02X-5.0Y20.0I10.0J0.0;
G01X4.1319;
G40H000Y23.4367;
M99;

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DISCUSSION

Wire EDM machining (Electrical Discharge Machining) is an electro thermal

production process where a thin single strand metal wire, along with de-ionised water
(used to conduct electricity) allows the wire to cut through metal by the use of heat
from electrical sparks, while preventing rust. Wire EDM machining works by creating
an electrical discharge between the wire or the electrode and the work piece. As the
spark jumps across the gap, material is then removed from the work piece and the
electrode. Due to the inherent properties of the process, Wire EDM can easily
machine complex parts and precision components out of hard conductive materials.
To stop the sparking process from shorting out, a non-conductive fluid or dielectric is
also used in the process. The waste material is removed by the dielectric, and the
process continues.
First and foremost, an EDM machine is the machining of a material through
thedirection of high-frequency electrical spark discharges from a tool, usually made of
graphite. This graphite tool acts as an electrode that disintegrates
conductive materials in the machining process.
Basically, there's an electrode that passes a current through amaterial that
causes it to melt or vaporize, and that's how the machining is accomplished. However,
this process can't happen just anywhere, in fact the work piece and the electrode
must be submerged in a dielectric fluid. Under the main process of EDM, there are
three sub processes. Those are Wire EDM, Sinker EDM, and Hole Drilling EDM.
Briefly, the sinker EDM process uses an electrically charged electrode that is
configured to a specificgeometry to burn the geometry of the electrode into a metal
component. The sinker EDMprocess is commonly used in the production of dies and
molds. In the other hand, the drillhole EDM processes uses an energized rotating tube
electrode with high pressure flushingto produce fast and accurate machining of small
deep holes inconductive metals.

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CONCLUSION

In conclusion, from this workshop we able to accomplish the objectives which is

acknowledge machine process capabilities and limitation. The wire-cut electrical
discharge machining plays an important role in manufacturing sectors especially
industries like aerospace, ordinance, automobile and general engineering. Since the
speed of the cutting increase, the time taken to finish the product will decrease. So,
with the right application, cutting speeds, the process could be done faster, and it is
possible to increase the productivity of parts.
EDM Wire Cut machine with skill and know how to enter the program and run
machine for the design of the products made. EDM Wire cutting process based on the
principal energy mode is thermal with the electrical discharge. Special brass wires are
typically used and usually performed in a bath of water. Astechnology advances in
speed, work piece size and geometry complexity, accuracy, ease of use, unattended
operation, industry education and affordability. In the case of complicated shapes
requiring cuts or angled, conical, or other unusual surface, the upper and lower wire
guide systems carry out differing movements accordingly.

REFERENCE
• https://headland.au/how-does-wire-edm-work/
• https://waykenrm.com/blogs/wire-edm-process/
• https://www.thomasnet.com/articles/custom-manufacturing-fabricating/Wire-
Cut-EDM/
• https://en.wikipedia.org/wiki/Electrical_discharge_machining
• Elman Jameson, (2010, October 01). Electrical Discharge Machining. Society
of Manufacturing Engineers

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